Method for determining the angular position of a rotor

ABSTRACT

According to the invention, in a method for determining the angular position of a rotor, a reference voltage is set in a calibration phase, such that when the rotor, rotating at a calibration speed, passes through a particular detection position, said voltage is the same as the electromotive force induced in the one winding coil. In a subsequent measuring phase the reference voltage is updated to a value (U R ) which is equal to the product of the voltage value set in the calibration phase and the ratio of the instantaneous motor rotational speed to the calibration rotational speed. The angular position of the rotor (ω 1 ) at which the electromotive force corresponds to the updated reference voltage is thus identified as the detection position.

The invention relates to a method for determining the angular position of a rotor according to the preamble of patent claim 1.

Such a method is, for example known from EP 647,014 B1. The known method serves for ascertaining the angular position of the rotor of a brushless motor. Brushless motors are electronically commutated motors. The winding coils of these motors are energized in a cyclic sequence respectively during a predeterminable current flow angle synchronously to the angular position of the rotor. The angular position is thereby ascertained by determining the electromotive forces which are induced in the winding coils and which depend on the angular position of the rotor and by detecting the zero crossings of the electromotive forces. The determination of the electromotive forces is thereby accomplished by measuring the coil voltages present at the winding coils. Thereby, it is a detriment that the electromotive forces can be ascertained only at certain time intervals during which the respective winding coils do not carry a current. Thus, the zero crossings of an electromotive force can be determined only when these forces are present in time ranges in which the respective winding coil is not energized. Thereby, the control range of the current flow angle is substantially limited.

It is further known from EP 647,014 B1 that the angular position of the rotor can also be ascertained with special position sensors, particularly with Hall effect sensors. The position sensors and the effort and expense for the mechanical mounting of these sensors, however, represent a substantial cost disadvantage.

Thus, it is an object of the invention to provide a method according to the preamble of patent claim 1 which will yield precise results even for large current flow angles.

This object has been achieved by the features of patent claim 1. Advantageous embodiments and further developments are provided by the dependent claims.

According to the invention the angular position of the rotor in an electronically commutated motor is ascertained at high r.p.m.s in a two-stage method. Thereby, in a first stage which is a calibration phase, a reference voltage is produced at a determined motor r.p.m. which is the calibration r.p.m. The reference voltage is adjusted so that at a point of time at which the rotor passes through a determined detection position, the reference voltage corresponds to an electromotive force which is induced in one of the winding coils of the motor. The detection position thereby is a special angular position of the rotor at which, for the entire control range of the current flow angle, the electromotive force induced in the one winding coil is present at this winding coil as a coil voltage. Thus, this coil voltage is ascertainable by a voltage measurement. In a second stage which is the actual measuring phase, first the instantaneous motor r.p.m. is ascertained. The ascertaining of the motor r.p.m. thereby takes place by an ascertaining of the frequency of one coil voltage of the coil voltages present at the winding coils of the motor. Thereafter, the reference voltage is updated to a value which is equal to the product of its voltage value adjusted in the calibration phase and the ratio of the instantaneous motor r.p.m. to the calibration r.p.m. Next, the angular position of the rotor is ascertained at which the electromotive force induced in the one winding coil is equal to the updated reference voltage. This angular position is identified as the detection position.

In an advantageous embodiment of the method the calibration r.p.m. and thus the current flow angle is selected so small that the detection of zero crossings of the electromotive force induced in this winding coil is possible by evaluating the coil voltage present at the respective winding coil. These zero crossings are then detected during the calibration phase and based on the position of the zero crossings, those points of time are ascertained at which the rotor runs through the detection position.

The calibration phase is preferably cyclically repeated. Thereby, the reference voltage is adapted to the temperature dependent changes of the electromotive forces.

The method according to the invention has a cost advantage compared to a method in which the angular position of the rotor is ascertained with special position sensors because, according to the invention, these sensors are not necessary and thus any work effort for mounting and for precisely positioning such sensors is obviated. Additionally, the present method provides precise results because no mechanical tolerances which are unavoidable in connection with using position sensors, enter into the evaluation.

The method according to the invention is very well suited for controlling of four coil brushless motors which are, for example used in motor vehicles for driving cooling fans.

The invention will be explained more closely in the following with reference to an example embodiment and with reference to the figures. These Figs. show:

FIG. 1 a block circuit diagram with an electronically commutated motor and a control device for this motor;

FIG. 2 is a schematic illustration of signals for explaining the commutating procedure;

FIG. 3 is a schematic illustration of signals during a calibration phase; and

FIG. 4 is a schematic illustration of signals during a measuring phase.

FIG. 1 shows, as an example embodiment, a block circuit diagram of an electronically commutated motor 10 and a block circuit diagram of a control device for regulating (controlling in closed loop fashion) the r.p.m. of the motor 10.

The motor 10 comprises a permanent magnetic rotor 15 and a stator with four winding coils A, B, C and D. Two each of these winding coils are combined to a coil pair A, B or C, D, whereby the coil pairs A, B or C, D are wound on a respective tooth. The winding coils A, B or C, D of the respective coil pair are wound in bifilar parallel fashion and produce, when energized, magnetic fields of opposing polarity. The motor 10 is energized out of a DC voltage source, for example out of a vehicle battery. The winding coils A, B, C, D are connected for this purpose with one terminal to a common circuit node. A battery voltage U_(B) provided by a DC voltage source is present at this circuit node. The opposite terminal ends of the winding coils are connected through a control transistor, for example a field effect transistor T_(A) or T_(B) or T_(C) or T_(D) with a ground terminal M.

The winding coils A, B, C, D are energized in a cyclic sequence respectively during a predeterminable electrical current flow angle α through the control transistors T_(A), T_(B), T_(C) and T_(D). A control device 20, 21, 22 generates control impulses for the sequentially correct controlling of the control transistors T_(A), T_(B), T_(C) and T_(D). The control signals are supplied to the control inputs of the control transistors T_(A), T_(B), T_(C) and T_(D) as control signals U_(GA), U_(GB), U_(GC), U_(GD).

The control device comprises a processing stage 21 which ascertains the instantaneous motor r.p.m. n_(ist) based on the coil voltages U_(SA) and U_(SC) of the winding coil A and the winding coil C. The control device further generates a trigger signal U_(T) which marks the point of time at which the rotor 15 passes through a determined angular position φ. The control device further comprises a driver unit 20 for producing the control signals U_(GA), U_(GB), U_(GC) and U_(GD). The control device further includes a closed loop control stage 22 for triggering the driver stage 20. The closed loop control stage 22 comprises in its turn a comparator 23 which compares the instantaneous motor r.p.m. n_(ist) with a predetermined rated r.p.m. n_(soll). The stage 22 further includes an evaluating unit 24 which produces, based on the r.p.m. comparing result and on the trigger signal U_(T), correctly timed signals U_(25A), U_(25B), U_(25C) and U_(25D) for the driver unit 20. The closed loop control stage 22 may further comprise means for ascertaining the current flowing through the winding coils A, B, C and D and means for passing on the current information to the evaluating unit 24. The current may, for example, be ascertained with a shunt resistor provided in the grounding circuit branch of the control transistors T_(A), T_(B), T_(C) and T_(B).

The commutating of the motor 10 can be explained with reference to FIG. 2. FIG. 2 shows the signals as a function of the angular position φ=ωt of the rotor 15. The upper diagram shows the electromotive forces U_(EMK),_(A), U_(EMK),_(B), U_(EMK),_(C), U_(EMK),_(D) induced in the winding coils A, B, C and D. Therebelow are shown the control signals U_(GA), U_(GB), U_(GC) and U_(GD) which are supplied to the control transistors T_(A), T_(B), T_(C) and T_(D). The pulse widths of these control signals U_(GA), U_(GB), U_(GC) and U_(GD) correspond to the current flow angle α of the respective control transistor T_(A), T_(B), T_(C) and T_(D). The pulse widths determine the motor r.p.m. n of the motor 10. The motor r.p.m. n may be increased from a low r.p.m. n₀ to a high r.p.m. n₁ by increasing the current flow angle α in the manner shown by dashed lines. Below the control signals U_(GA), U_(GB), U_(GC) and U_(GD) there are shown working sections A₀, A₁ of the coil pair A, B at a low r.p.m. n=n₀ or at a high r.p.m. n=n₁. The working sections A₀, A₁ include different angular sectors K₀, K₁, K₂. Within the angular sections K₀ the winding coil A as well as the winding coil B wound onto the same tooth are switched off. In the angular sections K₁ either the transistor T_(A) or the transistor T_(B) is switched into the conducting state for energizing the winding coil A or the winding coil B. The angular sections K₂ represent areas in which, following switching off the transistors T_(A) or T_(B), the winding coil A or the winding coil B is decommutated.

The electromotive forces U_(EMK),_(A) or U_(EMK),_(B) or U_(EMK),_(C) or U_(EMK),_(D) induced in the winding coils A, B, C and D, exhibit respectively a characteristic curve that is determined by the angular position φ. These electromotive forces are present at the respective winding coil as coil voltages and can be measured in these angular sections by a simple voltage measurement. The angular sections relate to the respective winding coil and the winding coil wound onto the same tooth which are not switched on during these angular sections. For example, the electromotive force U_(EMK),_(A) induced in the winding coil A is present as a coil voltage U_(SA) at the winding coil A when no current is flowing through the winding coil A nor through the winding coil B, thus, in the angular sections K₀. This angular section K₀ is large for a small current flow angle α and thus at a small r.p.m. n₀. This angular section K₀ embraces a range of the electromotive force U_(EMK),_(A) in which this electromotive force exhibits a zero crossing φ₀*. This zero crossing neither depends on the r.p.m. nor on the temperature. Compared thereto the angular section K₀ at the high r.p.m. n₁ is very small and then embraces a range of the electromotive force U_(EMK),_(A) in which this force does not exhibit a zero crossing. In this range the electromotive force U_(EMK),_(A) depends on the r.p.m. and on the temperature.

In order to also make possible a precise ascertaining of the angular position α of the rotor 15 at high motor r.p.m.s at which the zero crossings of the electromotive forces are not visible as coil voltages, a calibration of the control device is first performed.

The calibration procedure is best described with reference to FIG. 3. In this Fig. the signals are also shown as a function of the angular position φ=ωt of the rotor 15. The upper diagram shows the electromotive forces U_(EMK),_(A), U_(EMK),_(B), U_(EMK),_(C) and U_(EMK),_(D) induced in the winding coils A, B, C and D. The control signals U_(GA), U_(GB), U_(GC) and U_(GD) supplied to the control transistors T_(A), T_(B), T_(C) and T_(D) are shown therebelow. The measured voltages U_(A) and U_(C) are shown below the control signals. The measured voltages are present at the connecting point of the winding coil A with the control transistor T_(A) or respectively at the connecting point of the winding coil C with the control transistor T_(C).

The angular position ω₀ corresponds to the zero crossing of the electromotive force U_(EMK),_(C) and the angular position φ₀* corresponds to the zero crossing of the electromotive force U_(EMK),_(A). The angular position φ₁ is referred to in the following as the detection position. The detection position is selected in such a way that even at a maximum current flow angle α the detection position lies in an angular range in which the electromotive force U_(EMK),_(A) is present as a coil voltage U_(SA) of the winding coil A. The detection position φ₁, is spaced by a fixed, predetermined angular value Δφ or Δφ* relative to the zero crossing φ₀ or φ₀* of the electromotive force U_(EMK),_(C) or U_(EMK),_(A).

In the calibration phase the motor r.p.m. n is adjusted by controlling the current flow angle α, to a calibration r.p.m. n_(K) which is selected to be so small that the electromotive force U_(EMK),_(C) induced in the winding coil C is in the angular range in which it is present as coil voltage U_(SC) at the winding coil C and exhibits a zero crossing φ₀. The maintaining of the calibration r.p.m. n_(K) can thereby be checked by a frequency analysis of the measured voltage U_(A) or U_(c).

Thereafter, the zero crossing φ₀ is ascertained at a constant calibration r.p.m. n_(K). For this purpose the angular range is first ascertained in which the electromotive force U_(EMK),_(C) is present at the winding coil C as the coil voltage U_(SC). In this angular range the measured voltage U_(C) is compared with the battery voltage U_(B) and the angular position φ is identified as the zero crossing φ₀ when the measured voltage U_(C) is equal to the battery voltage U_(B). Alternatively, the zero crossing φ₀* of the electromotive force U_(EMK),_(A) can be detected by comparing the measured voltage U_(A) with the battery voltage U_(B). Then a threshold voltage U_(S) which equals the sum of the battery voltage U_(B) and a reference voltage U_(R) is compared with the measured voltage U_(A). The threshold voltage U_(S) is controlled in closed loop fashion by varying the reference voltage U_(R) in such a way that the threshold voltage U_(S) and the measured voltage U_(A) intersect each other at the detection position φ₁ which is spaced from the zero crossing φ₀ by the known angular value Δφ or which is spaced from the zero crossing φ₀* by the known angular value Δφ*. By this measure the reference voltage U_(R) is adjusted to a voltage value which is assumed by the electromotive force U_(EMK),_(A) when the rotor 15 passes through the detection position φ₁. This value is stored in an intermediate storage as the calibration value U_(kal).

The actual measuring takes place in a following measuring phase which will be described in more detail with reference to FIG. 4. In this Fig. the signals are also shown as a function of the angular position φ=ωt of the rotor 15. The upper diagram shows, as in FIG. 3, the electromotive forces U_(EMK),_(A), U_(EMK),_(B), U_(EMK),_(C) and U_(EMK),_(D) induced in the winding coils A, B, C and D. Thereunder the control signals U_(GA), U_(GB), U_(GC), U_(GD) and the measured voltage U_(A) are shown which are supplied to the control transistors T_(A), T_(B), T_(C) and T_(D). Thereby, the signals for a current flow angle α are shown. The current flow angle is selected so large that the zero crossing φ₀* of the electromotive force U_(EMK),_(A) is no longer visible as a coil voltage U_(SA).

During the measuring phase the instantaneous motor r.p.m. n_(ist) is first ascertained. Thereafter, the reference voltage U_(R) is updated to the value U_(Rakt), whereby the actualization takes place according to the equation U _(Rakt) =U _(kal)·(n _(ist) /n _(K))

In the equation U_(kal) is the voltage value of the reference voltage U_(R) adjusted in the calibration phase, n_(ist) is the instantaneous motor r.p.m. and n_(kal) is the calibration r.p.m. By the actualization of the reference voltage U_(R) the threshold voltage U_(S) is also updated to an r.p.m. dependent value, namely the value U _(S) =U _(B) +U _(kal)·(n _(ist) /n _(K))

Thereafter the angular position φ is ascertained in the angular range K₀ in which the electromotive force U_(EMK),_(A) is present as a coil voltage U_(SA) at the winding coil A. At the angular position φ the measured voltage U_(A) is equal to the updated threshold voltage U_(S). This corresponds to the ascertaining of the angular position φ at which the electromotive force U_(EMK),_(A) is equal to the updated value U_(Rakt) of the reference voltage U_(R). This angular position φ then is identified as the detection position φ₁.

In this manner it is possible to ascertain the angular position φ of the rotor 15 with a high accuracy even for large current flow angles α at which the zero crossings of the electromotive forces are no longer visible at the winding coils of the motor. 

1. A method for determining the angular position (φ) of a rotor (15) of an electronically commutated motor (10) having a plurality of winding coils (A, B, C, D) and in which the winding coils (A, B, C, D) are respectively energized in a cyclic sequence during a predeterminable current flow angle (α), characterized in: that an angular position (φ) of the rotor (15) is selected as detection position (φ₁) at which angular position an electromotive force (U_(EMK),_(A)) is induced in one of the winding coils (A) during the entire dynamic range of the current flow angle (α), said electromotive force being present as coil voltage (U_(SA)), that during a calibration phase the motor r.p.m. (n) is adjusted to a calibration r.p.m. (n_(K)) and that a reference voltage (U_(R)) is adjusted in such a way that the reference voltage is equal to the electromotive force (U_(EMK),_(A)) induced in said one winding coil (A) when the rotor passes through the detection position (φ₁) and that the instantaneous motor r.p.m. (n_(ist)) is ascertained during a measuring phase, that the reference voltage (U_(R)) is updated to a value that is equal to the product of its voltage value (U_(kal)) adjusted in the calibration phase and the ratio between the instantaneous motor r.p.m. (n_(ist)) and the calibration r.p.m. (n_(K)), and wherein that angular position (φ) of the rotor (15) is identified as detection position (φ₁) at which the electromotive force (U_(EMK),_(A)) induced in said one winding coil (A) is equal to the updated reference voltage (U_(R)).
 2. The method of claim 1, characterized in that the calibration r.p.m. (n_(K)) is selected so low that by evaluation of the coil voltage (U_(SA), U_(SC)) present at one of the winding coils (A, C), the detection of zero crossings (φ₀*, φ₀) of the electromotive force (U_(EMK),_(A), U_(EMK),_(C)) induced in the one winding coil is possible, and that the zero crossings (φ₀* or φ₀) are detected during the calibration phase, and that with the aid of their position the points of time are ascertained at which the rotor passes through the detection position (φ₁). 3-5. (canceled).
 6. The method of claim 1, characterized in that the motor r.p.m. (n) is ascertained by ascertaining the frequency of one of the coil voltages present at the winding coils (A, B, C, D).
 7. The method of claim 1, characterized in that the calibration phase is repeated several times during operation of the motor.
 8. The method of claim 1, characterized in that the electromotive force (U_(EMK),_(A), U_(EMK),_(B), U_(EMK),_(C), U_(EMK),_(D)) induced in one of the winding coils (A, B, C, D) is ascertained in that the coil voltage of the respective winding coil is evaluated in a time interval in which the winding coil and, if applicable, each further winding coil wound onto the same tooth is or are switched off. 